More accidents in distribution centres

The Hari Raya period is a peak season for retailers and logistics service providers (LSPs), where volumes in a fast moving consumer goods Distribution Centre (DC) are easily three times the average volume. This increase in workload unfortunately also results in a higher number of accidents in DCs. In fact, over the years there has been an increasing work pressure in DCs in Asia. This is the result of continuous costs reduction programs, high performance contracts between LSPs and customers, as well as the introduction of e-commerce, leading to an explosion in number of order lines (high volumes of small orders).  What are the most common accidents in DCs?

The most common accidents are slips and trips. Slips and trips happen because of loose objects or liquids on floors, height differences or ridges, and dark areas. Falls contribute as second in DC accidents. This can be falls from equipment as well as falls from loading bays, containers and trucks. Third is contact of warehouse staff or visitors with moving objects, moving parts of equipment, as well as collisions between vehicles. Fourth are accidents in distribution centres caused by falling objects due to inproper stacking of loads on pallets or cylindrical objects rolling off shelves. Fifth in accident ranking is fire. A fire jeopardises an entire operation and causes serious injury, or even fatalities. Many warehouses store potentially flammable or combustable goods, such as chemicals, that can fast become an uncontrollable fire. Poor electrial wiring is in many cases the trigger for a warehouse fire.

Companies can take several measures to bring down accidents in distribution centres.

1. Safety education. The highest number of accidents happens with temporary labour and new warehouse staff. Therefore the foundation of warehouse safety is first of all a sound safety education program and effective follow through for fresh staff.

2. Warehouse design.
The design of the building contributes to a safe working environment. This addresses of course the basics such as proper lining of walkways & crossings, signboards, fire sprinklers & extinguishers, and electrical wiring. Research shows that splitting of bulk and picking zones in a warehouse has next to efficiency advantages also safety advantages. Walking in concentrated pricking zone for order pickers means less walking, resulting in less slipping and tripping. Trucks do not enter the picking zones during picking shifts, where order pickers walk. Finally, racks at picking zones are lower, reducing the chance of falling objects hurting order pickers.

3. Mechanisation and automation in warehouses.
Mechanisation of internal transport in warehouses minimises movements by people and trucks. An example is the use of flow racks with separate filling and picking for order picking in a warehouse, as well as the application of conveyor belts in DCs. Conveyor belts can be used for moving loose picked goods or full pallets in a warehouse. Furthermore, full automation of bulk pallet handling could be attractive when there is a need for high storage volumes at great heights.

In short, several measures can be implemented to reduce the number of accidents in DCs and at the same time increase efficiency of your facility. It is worth the investment to have an external warehouse expert to help you with this. A safe and efficient working environment should be top priority!